Joining lengths of metal



Dec. 7, 1937. yH. J. SHARP JOINING LEGTHS OF METAL Filed April v, 1954,;

lNVENT-OR /J/M m. ma,

soldering,` Welding, or to the use of bolts.

lPatented Dec. 7, 1937 UNiTEo STATES PATENT orifice JorNING LENG'rns or METAL Application April` 7, 1934,'Sevral No. 719,475

14 Claims.

This invention relates to the joining of lengths of metal pieces and especially to framing and the construction of frames formed of metal and is applicable to the manufacture of frames for picture, display card. and bulletin board framing, and also to the manufacture of metal door frames and other like frame constructions, as Well as other uses where lengths of metal are joined together, either at an angle or incline.

Metal frames and other articles formed of extruded metal strips have heretofore been constructed, but considerable diihculty has been experienced in the forming of the joints or corners. Some metals can be successfully soldered, but other metals, such as aluminum, cannot be satisfactorily soldered. Welding can .be used in some instances, particularly where the metal is thereafter painted, so that /the discoloration caused bythe' heat of welding is covered by the paint. This is not desirable, however, where the natural finish of the metal is to be maintained or where the metal is provided with some special surface treatment which is detrimentally aected by the heat of welding. The use of bolts is not desirable because the heads of the bolts are difficult' to conceal at the front of the frame. According to the prsent invention, there is provided a connector element of a harder character than the elements to be joined and which interlocks therewith to make a tight joint. Moreover according to a preferred embodiment of the present invention, there is provided a metal framing strip which can be formed by extrusion and which is provided with continuous means extending along the back thereof for use in forming the joint whereby the strip `can be cut at any point in its length and such longitudinally extending means is available for making the joint.

The invention further contemplates the provision of a joint formed through the cooperation of such longitudinally extending means and separate metal connectors. The invention provides a method by means of which one constructing a frame may buy lengths of strip, cut them to any desired size and secure them together in a firm and rigid manner without resorting to v The invention may be readily understood by reference to the accompanying drawing, in which -Figure l represents a front view of a frame corner constructed in accordance with my invention, a part of the front of the `frame being broken away to show a part of the fastening means for the corner,

(ci. 18s- 36) Figure `2 represents a transverse vertical section in the plane of line H-II of Figure 1;

Figure 3 shows the same corner construction in rear elevation;

Figure 4 is a perspective view of one of the fastening members;

Figure 5 is a perspective view of another of the fastening members;

Figure 6 is a view similar to Figure 3 showing the application of my invention to the formation of corners which are less than 90;

Figure '7 is a perspective view of the strip from which the frame shown in Figures 1, 3, and 6 is constructed;

Figure 8 is a view similar to Figure 3 of a slightly different arrangement for use with widerframe strips;

Figure 9 is a perspective view of a portion of theV strip from which the corner of Figure 8 is formed;

Figure 10 is a, perspective view of one of the connectors used in making the corner shown in Figure 8; and

Figure 11 is a perspective view, partly broken away, of a further modication.

Referring' rst to the construction shown in Figures 1 to 7, there is shown in Figure 7 an extruded metal strip which may be of indefinite length. It is provided with a face or border portion 2 and a side or flange portion 3. It may have Vany desired external contour, the various steps or ribs on the outer surface of the border portion shown in Figure 7 being provided for ornamentation. On the inner surface of the border or front portion of the frame strip is a channel l having one'side formed of a longitudinally extending upstanding rib 5, this rib being relatively thin in cross section. The other side of the channel i is formed by an upstanding flange 6 having an overhanging lip portion 6a. The flange or side portion 3 of the strip is also in the form of a channel on the inner face of the strip, the channel being designated l. One side of the channel l is formed by a ange 8 having an overhanging lip 8a., while the other side of the channel is formed by a portion ofthe border portion 2 ofthe strip. A small ledge i)l extends longitudinally along theinner surface of the portion 2 of the strip parallel with the rib 5 and oppositeI the 'lip 8a. This cross-sectional shape of the strip is the same so that the strip can becut at any place in its length and present the same crosssectional shape. For instance, assuming that a right angle corneris to be formed, the strip may be cut diagonally along the line A--A in Figure 7.

Another portion of the strip may be cut along the line B-B whereby the two mitred surfaces may be brought together as shown in Figure l to form a right angle corner.

For securing the pieces together, two fastening members are preferably employed. One of these is shown in Figure 4 and the other is shown in Figure 5. 'I'he fastening member in Figure 5 comprises a flat angle member Il formed to a sharp right angle, or other angle in the event that the corner being constructed is not a right angle. The angle member has a width considerably in excess of its height so that it is very rigid.

It is preferably provided with notches or otherirregularities II in the outer edges of the two legs thereof. The other connecting member shown in Figure 4 is also an angle member I2. It is conveniently formed by bending a strip of metal to the proper angle. and its width is relatively slight as compared with its height. It may be termed an "upstanding angle while the one shown in Figure 5 may be termed a flat angle member. Small barbs are preferably formed on the edges of the two arms of the'angle member. These barbs are inclined away from the ends of the angle member toward the corner. They are designated by the numeral I3, and they may be conveniently formed by nicking the metal with a cold chisel or other suitable implement. In assembling the corner, one of the arms of the member I2 is forced to its full length into the channel I of one of the two meeting pieces. The barbs serve to increase the frictional Vengagement between the member I2 and the channel in which it is received, to make it extremely difficult to pull the angle member out after it has once been driven in. The framing strips themselves are ofa metal such as aluminum, which is relatively soft, while the connector member I2 is of -a hard metal, such as steel, and the barbs I2 possess some resilience. When the hard metal connector is forced into the slot or recess provided for it in the main frame members, the teeth or barbs on the surface of the hard metal member will so grip the body of the softer member as to make it very diiiicult to separate the members so joined. Likewise, the one leg of the angle member I0 is inserted in one of the channels 4 on the border portion of one of the meeting strips. The rib 5, which is more or less ductile and which is of small cross section, is then peened over'into the notches II. This may be conveniently done through the use of a hammer and punch. As shown in Figure 3, the metal winch is thus peened over o'r punched into the notches II at points I4, form keys which tightly interlock the member I0 against movement in the channel 4. When me two angle members III and I2 have thus been secured to one of the two meeting strips, the other arms of the two angle members I0 and l2 are entered in the respective channels 4 and I of the other strip. When the meeting edges of the two pieces are brought together as shown in Figure 1, the barbs I3 serve to prevent the joint from spreading, and the rib 5 of the second piece is then punched or peened in to interlocking engagement with the other arm of the angle member I0 and the joint is complete.

It will thus be seen that after the ends of the strips have been mitred to the desired angle, a joint can be very easily and simply formed, and the joint having once been formed cannot, without excessive abuse, be separated or destroyed. The joint can be easily made without marring the iinish of the strip, and from the front of This keeps the frame fiat.

the frame all of the fastening means are concealed. The labor cost i'or making a frame is reduced to a minimum, while the cost of extruding the strip is very little more than the cost of extruding framing strips as heretofore constructed.

A definite advantage arises from the provision plane of the metal. It therefore serves to effec-1 tively resist strains tending to open or spread the joint. The connector member I2, on the other hand, has its maximum strength in a direction at right angles to the plane of the maximum strength of the connector Il. It therefore serves to effectively prevent bending of the frame in a direction transverse to the plane of the frame. By positioning one of the connecting members adjacent the outside of the corner and the other one relatively close to the inside of the corner, the corner is further reinforced against spreading, and the meeting ends of the two pieces are held in contact along their entire length.

It is obvious that the connector members I! and I2, in addition to being formed to right angles, may be formed to various other angles so that hexagonal, octagonal, triangular and other shape frames can be produced. This is illustrated in Figure 6 wherein Il la designates a connector corresponding to theconnector Il of Figure 5; but bent to a lesser angle than 90. The

A numeral I2a designates a connector corresponding to connector I2, but bent to an angle corresponding to the angle of the member Illa.

As a modification which is sometimes better suited to frames of considerable width, the arrangement shown in Figures 8 and 9 may be employed. In Figure 9, the contour of the strip is shown. As mentioned in connection with Figure 7, the outer contour or ornamental ribs or steps, is not important. The strip has a border or face portion I5 corresponding to the portion 2 of Figure 7, and a flange or side portion I6 corresponding to the part 3 of Figure 7. The side portion I6 is provided with an internal channel Il having flanged edges, the cross-sectional shape of the side portion I6 corresponding to the crosstively thin upstanding flanges I8 and I8 between which is a relatively wide channel 20. In forming the Joint or corner, a connector 2|, similar in all respects to the connector I2, has its arms entered into the channel portions I1 of the meeting members. A relatively wide dat angie piece or plate 22 is provided which may be laid into the channel 2l after the meeting pieces have been joined by the member 2i. The flat angle member 22 is provided along one, and preferably both, edges with a series of notches 23. After this member has been laid in the Achannel 2l, the flanges Il a'nd I9 may be punched or dented in-so as to interlock with the notches or recesses 23.

(iii

having a border pbrtion with a channel on thethat the member 22 can be laid into the channel 20 after the meeting ends havelbeen brought tightly together and held by the member 2|, whereas in the construction shown in Figures 1 to 7, the overhanging ange or lip 6a prevents the angle member i from being laid into the channels 4 after the strips have beenv brought together. Y

In.'this modification also, the member 2| is `at the outside of the joint, whereas the inner edge of the member 22 is preferably relatively close to the inside of the Joint. The two connecting members in this form. as in the previous form, are disposed in planes which are at right angles to each other so as to stiffen the frame against distortion. The relatively wide plate 22 in this form of joint naturally has a greater resistance to bending in the direction ofits width than does the relatively smaller connector of Figure 5. 1 For this reason also, it may be preferred in use with frames of larger sizes.

In Figure 11, I have shown two members of like cross section joined together in end to end relation. The two parts which are connected are indicated as being of substantially circular` cross section, and they are designated 30 and 3|. They are formed of a relatively soft metal with a hollow interior, being tubular. They are connected by means of a connector member 32. The member 32 is formed of relatively harder metal. shown as being tubular and as having b'arbs about the periphery thereof, the barbs at opposite sides of the metalbeing sloped in different directions, both sets of barbs being pointed toward the middle of the connector. The connector is slotted longitudinally whereby it can be compressed to facilitate its insertion in the ends of the two members to be joined. It is resilient so that when it is released it tends to spring back to its normal diameter. The barbs on the harder member penetrate the softer metal, as previously described in connection with member I2. This 'type of joint witntubular elements has particular utility in -connection with extruded hand rails. stair banisters, and the like.

While many of the joints herein specifically iilustratedare right angle joints, it will be understood that the invention is not restricted to a rightangle joint, but may have any other angle as illustrated, for instance, by Figure 9, and the term mitred as used in the appended claims-is intended to include any angular Joint, whether a 45 angle or not.

While I have illustrated my invention as applied to a frame of particular cross-sectional shape, it will be understood thatthis is merely by way of illustration. It will also be apparent that various changes and modifications may be made in the detailed construction and arrange ment of parts within the contemplation of my invention and under the scope of the following claims.

Iciaim: A

l. A framing construction comprising framing strips having mitred ends which abut, each strip having a border portion and a side portion, each of said portions having a longitudinally extending channel therein, a. -connector comprising a rigid angle member in each of said channels having the legs thereof received in the channels of the abutting strips, at least one side of one of the channels and one edge of one of the connectors having interlocking portions.

2. A framing construction comprising framing strips having mitred ends which abut, each strip Itisunder'surface thereof, `and a rigid angle member side of the channel 'of each strip being peened into said notches to effect such interlocking1 engagement.

3. A framing construction comprising framing strips having mitred ends which abut, each strip having a border portion with a channel on the under surface thereof, and a rigid angle member having its legs received in the channels of the abutting strips, the channel and the connector having interlocking engagement, said connectorhaving notches in at least one edge thereof, one side of the channel of each strip being peened into said notches to effect such interlocking engagement, said strips also having side portions with channels on the inner surfaces thereof, and other angle members received in the channels of the side portions, the angle members in the side portions being perpendicular to said first named Iangle members.

4. A framing construction comprised of framing strips having mitred end's which abut, thereby forming a corner, each strip having a border .portion and a side portion, each of said portions the channel of the abutting border portions, the e angle members of each corner being in planes which are perpendicular to each other, and means forming an interlocking engagement between the -angle members in the channels of the border portions and the sides of such channels.

5. A framing construction comprised of framing strips having mitred ends which abut, thereby forming a corner, each strip having a border portion and a side portion, each of said portions having a longitudinally extending channel therein, and a connector'in each corner received in the channels of the abutting side portions, each corner having a connector therein received in the channel of the abutting border portions, the

the side of the channel being bent into the notches to form such interlocking means.

6. A frame construction comprising framing strips having mitred ends which abut to form a corner, each strip having a border portion and a side portion, the border portion having a channel therein, the side portion having a channel therein, each corner having a connector received in the abutting channels of the side portions,

each corner having an angle member in the channels of the abutting border portions, the last named angie member having notches in the edge thereof, at least one side of the channel having portions which extend -into the notches,v

to form an interlocking engagement between the angle member and the strips.

7. A frame construction comprising framing strips having mitred endsl which abut to form a-corner, each strip having a border portion and a side portion, the border portion having a channel therein, the side portion having a channel therein, each corner having a connector received in the abutting channels of the side portions, each corner having an angle member in the channels of the abutting border portions, 'the last named angle member having notches in the edge thereof, at least one side of the channel having portions which extend into the notches to form Aan interlocking engagement between the angle member and the strips, the angle members in the channels of the side portions having barbs for resisting removal from the channels in which they are received.

8. A frame comprising a plurality of framing strips of similar cross-sectional shape having a border portion and a side portion, the side portion having a continuous channel therein extending longitudinally thereot, the inner iace of the border portion also being provided with a channel, and connector members entered into the registering channels br abutting ends, one connector at each joint having interlocking engagement with the walls of the channel with which it contacts.

9. A frame comprising a plurality oi abutting lengths of strips, each strip having a border portion and a side portion, the side portion having a continuous channel therein extending longitudinally thereof, the inner i'aceof the border portion also being provided with a continuous longitudinal channel, at least one side of said last named channels having a side wall comprising a rib of relatively thin crosssection capable oi' being distorted into inter-locking engagement with a connector, and two connectors at each Joint between abutting ends, one connector being received in the registering channels of the side portions and the other connector being received in the-registering channels in the border portions, said last connector having means along its edges for interlocking engagement with said rib.

10. A frame comprised oi a plurality o! lengths of strip having angular abutting ends, all ci the strips being of similar cross-sectional shape and size, each strip having a border portion and having a longitudinally extending continuous channel on the under face thereof, one side of said channel comprising a relatively thin ilange of metal spaced inwardly from the edges oi' the strip and capable of being distorted into coopn eration with a connectormember received in said I channel without such distortion being visible from the exterior of the frame, and a connector inthe channels of abutting strips having edge portions which are forced into engagement with said relatively thin flange-like side wall of the channel.

l1. A frame comprised of a plurality of fraining strips of similar cross-sectional shape and having angular ends which are in abutting relation, each strip having a border portion and having a continuous longitudinally extending chanside walls of the channel, the distortion of the side walls being invisible at the iront oi the frame. I

12. A framing strip having a face or border portion terminating at its inner edge in a relatively thin edge portion and provided at its outer edge with a side portion, the inside face o! the side portion having a longitudinally extending continuous channel therein, the side walls oi' said channel having overhanging ilange portions, the inner face oi' the border portion also having a longitudinally extending continuous channel therein, said channel serving to receive connectors at any point where the strip is severed.

13. A frame comprising a plurality of angularly abutting framing strips of like cross section, said strips having registering face or border portions and registering outer side wall portions, the inner faces of the border portions having longitudinally extending channels therein, the inner faces ot the side portions also having longitudinally extending channels therein, said last mentioncd channels having overhanging ilanges thereon, angular corner connectors iltted into the channels in the side wall portions and retained against displacement by the overhanging flanges on the sides oi said channels, and angular connector members in the channels of the abutting border portions.

14. A frame comprising a plurality of angularly abutting framing strips of like cross section, said strips having registering face or border portions and registering outer side wall portions, the inner faces of the border portions having longitudinally extending channels therein, the inner faces of the side portions also having longitudinally extending channels therein, said last mentioned channels having overhanging ilanges thereon, angular corner connectors fitted into the channels in the side wall portions and rctained against displacement by the overhanging ilanges on the sides of said channels, and angular connector members in the channels of the abutting border portions, said rst connectors being substantially perpendicular to the plane of the face of the frame and the second angular connectors lying substantially parallel to the faccio! the frame.

HENRY J SHARP. 

